Maxwell Freedom 800 Operating instructions

Brand: Maxwell

Model: Freedom 800

Type: Operating instructions

Maxwell Freedom 800 is a powerful windlass with a maximum pull capacity of 3000 lbs (1361 kg), making it suitable for boats up to 60 ft (18 m) in length. It can be used to retrieve anchors, raise and lower sails, and tension mooring lines. The windlass features two speeds, allowing for both quick retrieval and precise control. It is equipped with a manual override in case of power failure, and a circuit breaker to protect the motor.

Freedom Windlass

Installation and Operation Manual

 Copyright Maxwell Marine International, 2008.

Maxwell Marine International reserves the right to make

engineering refinements on all products without notice.

Illustrations and specifications are not binding as to detail.

Part No: P103102

160210

Freedom Windlass 1

Table of Contents

Preliminary Information .............................................................................................................. 2

Introduction ............................................................................................................................... 2

Components ............................................................................................................................. 2

General Layout ......................................................................................................................... 3

Important Safety Information .................................................................................................... 4

Identifying your Windlass ......................................................................................................... 5

Parts of the Windlass ............................................................................................................... 7

Parts of the Gearbox and Capstan ........................................................................................... 8

Parts List .................................................................................................................................. 9

Ordering Spare Parts ............................................................................................................. 11

Rope and Chain Selection Guide ........................................................................................... 12

Installation .................................................................................................................................. 13

General Requirements ........................................................................................................... 13

Installation Instructions ........................................................................................................... 16

Rope Splicing Notes ............................................................................................................... 19

Wiring Instructions .................................................................................................................. 20

Operation .................................................................................................................................... 25

Loading the Rope/Chain ......................................................................................................... 25

Anchoring Tips ....................................................................................................................... 25

Lowering the Anchor............................................................................................................... 26

Raising the Anchor ................................................................................................................. 26

Free falling the Anchor ........................................................................................................... 26

Raising the Anchor Manually .................................................................................................. 26

Using the Capstan Drum for Rope Warping .......................................................................... 27

Maintenance ............................................................................................................................... 28

Trouble Shooting Guide ........................................................................................................... 31

Reference Information .............................................................................................................. 32

Specifications ......................................................................................................................... 32

Dimensions ............................................................................................................................. 33

Typical Greasing Instructions ................................................................................................. 34

Additional Resources

The following resources are included at the back of this manual:

Deck Drilling Template

Deck Drilling Template - Performance Plate

Warranty Form

Contact Details (on back cover)

2 Freedom Windlass

Preliminary Information

Introduction

Congratulations on your purchase of a Maxwell Freedom windlass. Please read these instructions

carefully to enable you to correctly install and maintain the windlass for years of trouble-free

operation.

Note

Failure to follow the correct installation, operation or maintenance instructions will jeopardise your

safety and also invalidate the warranty.

Components

In addition to this instruction manual, the following components are included with the Freedom

windlass:

• Windlass in two components:

• Topworks assembly

• Motor and gearbox

• Remote up/down control panel

• Circuit breaker/isolator panel

• 12V or 24V reversing solenoid

• Manual crank handle

• Performance plate

• Deckplate gasket

• Small parts:

• Nuts

• Flat washer

• Spring washer

• Key

• Quick release clip

• Spare pressure arm kit

These components are illustrated in “Figure 1 - Freedom windlass components” on page 3.

Freedom Windlass 3

Figure 1 - Freedom windlass components

(Optional extras include: footswitches, warping capstan and rope/chain counter).

General Layout

Solenoid pack

Footswitch

Remote control

panel

Circuit breaker/isolator

Battery

+ -

Figure 2 - General layout

4 Freedom Windlass

Important Safety Information

• Make sure your windlass has been correctly specified before installation. Personal safety

may depend on it. The windlass must have a maximum pull capacity of at least three times

the combined weight of the anchor and chain.

• Correct fit of the chain to the chainwheel is essential. See "Rope and Chain Selection Guide"

on page 12.

• Keep hands, feet, loose clothing and hair well clear of the windlass and rope/chain during

operation.

• While raising the anchor, run the boat's engine above idle. This will minimise the power drain

on the batteries.

• Never operate the windlass from a remote station without having a clear view of the windlass.

• Do NOT use the windlass as a bollard. When anchoring or mooring, secure the line directly

to a bollard or deck cleat.

• Do NOT use the windlass to pull the boat forward when raising the anchor. Use the boat's

engine to drive the boat up to the anchor.

• Do NOT attempt to break free a fouled anchor with the windlass. Secure the line to a bollard

or cleat and use the boat's engine to break the anchor out.

• Always firmly tie down the anchor when under way or in heavy seas. Do not rely on the

windlass as a securing device.

• Always turn the circuit breaker/isolator switch off when the windlass is not in use and before

you leave the boat.

• Keep the anchor rope/chain in good condition, free from knots and twists. Inspect the rope

regularly for chafe. Where this has occurred, repair by cutting away the affected portion and

re-splice.

Tip: The rope can be swapped end-for-end to extend its life.

• Tie the end of the anchor rope/chain rode to a secure fixture in the chain locker.

• Do NOT use the windlass to haul a person up a mast.

Freedom Windlass 5

Identifying your Windlass

Before ordering spare parts, use the steps below to identify the model of your windlass.

1. Standard or Capstan

There are two different styles of Freedom windlass – standard (low profile) and capstan.

Standard Capstan

Figure 3 - Standard and capstan versions

2. Chainwheel identification

To determine which model of chainwheel you have look at the number in the bi-square on the top of

the windlass as shown below. There are 4 models of chainwheel: Freedom 500, 500M, 800 and

800M.

Freedom 500

Figure 4 - Chainwheel identification

6 Freedom Windlass

3. Motor size – 500 and 800 and Voltage – 12V and 24V

To determine whether you have a 12 Volt or 24 Volt motor, check the badge on the motor.

Freedom 500 - 600W 12V and 24V Freedom 800 – 1000W 12V and 24V

Figure 5 - Motor variants

4. Deck clearance

To determine the deck clearance of your windlass, measure from the bottom of the deckplate to the

centreline of the motor (DMC = Deck to Motor Centreline).

154mm DMC

For decks up to 65 mm thick 254mm DMC

For decks up to 165 mm thick

Figure 6 - Deck clearance variants

Freedom Windlass 7

Parts of the Windlass

Figure 7 - Parts of the windlass

8 Freedom Windlass

Parts of the Gearbox and Capstan

Figure 8 - Parts of the gearbox and capstan

Freedom Windlass 9

Parts List

Before ordering parts, please refer to "Identifying your Windlass" on page 5.

Item Description Qty Part to order Includes items

1 Handle 1 131/AI 1

2 M8 x 16 cheese head screw 1 P100087 2, 3, 5, 10, 16, and 18

3 M8 x 17 flat washer 1 P100087 2, 3, 5, 10, 16, and 18

4 Clutch nut 1 4376 4

5 Tab washer 1 P100087 2, 3, 5, 10, 16, and 18

6 Snap bush 1 See item 8 6 and 8

7 Chain wheel upper 500 1 P100030 6, 7, 8 and 9 see page 12 for rode selection guide

7 Chain wheel upper 500M 1 P100031 6, 7, 8 and 9 see page 12 for rode selection guide

7 Chain wheel upper 500MA 1 P100032 6, 7, 8 and 9 see page 12 for rode selection guide

7 Chain wheel upper 800 1 P100033 6, 7, 8 and 9 see page 12 for rode selection guide

7 Chain wheel upper 800M 1 P100034 6, 7, 8 and 9 see page 12 for rode selection guide

8 500 stripper 1 P100084 6 and 8

8 800 stripper 1 P100085 6 and 8

9 Chain wheel lower 500 1 P100030 6, 7, 8 and 9 see page 12 for rode selection guide

9 Chain wheel lower 500M 1 P100031 6, 7, 8 and 9 see page 12 for rode selection guide

9 Chain wheel lower 800 1 P100033 6, 7, 8 and 9 see page 12 for rode selection guide

9 Chain wheel lower 800M 1 P100034 6, 7, 8 and 9 see page 12 for rode selection guide

10 Belleville washer 1 P100087 2, 3, 5, 10, 16, and 18

11 Pressure arm clip 1 P100019 11, 12, 13, and 14

12 Clip insulator 1 P100019 11, 12, 13, and 14

13 Pressure arm blade 2 P100019 11, 12, 13, and 14

14 Pressure arm spine 1 P100019 11, 12, 13, and 14

15 Shaft 154mm DMC 1 P100016 15, 16, 17 and 18

15 Shaft 254mm DMC 1 P100047 15, 16, 17 and 18

15 Shaft 154mm DMC - capstan 1 P100017 15, 16, 17 and 18

15 Shaft 254mm DMC - capstan 1 P100048 15, 16, 17 and 18

16 O-ring 18 x 2mm 1 P100087 2, 3, 5, 10, 16, and 18

17 Clutch cone 1 See item 15 15, 16, 17 and 18

18 Quad ring 1 P100087 2, 3, 5, 10, 16, and 18

19 Plug 1 *P100022 or P100049 11, 12, 13, 14, 19, 20, 21, 22, 25, 26, 27(x3), 28(x3),

29(x3), 30(x3), 31, 32, 33, and 34

20 Deckplate bearing 1 *P100022 or P100049 11, 12, 13, 14, 19, 20, 21, 22, 25, 26, 27(x3), 28(x3),

29(x3), 30(x3), 31, 32, 33, and 34

21 Spacer tube retaining collar 1 *P100022 or P100049 11, 12, 13, 14, 19, 20, 21, 22, 25, 26, 27(x3), 28(x3),

29(x3), 30(x3), 31, 32, 33, and 34

22 Deckplate 1 *P100022 or P100049 11, 12, 13, 14, 19, 20, 21, 22, 25, 26, 27(x3), 28(x3),

29(x3), 30(x3), 31, 32, 33, and 34

23 Gasket 1 4169 23

24 Performance plate 1 4517 24

*P100022 = 154mm DMC, P100049 = 254mm DMC. See "Figure 6 - Deck clearance variants" on page 6.

(Parts list continued on next page)

10 Freedom Windlass

Parts List (continued)

Item Description Qty Part to order Includes items

25 Deckplate insert 1 *P100022 or P100049 11, 12, 13, 14, 19, 20, 21, 22, 25, 26, 27(x3), 28(x3),

29(x3), 30(x3), 31, 32, 33, and 34

26 Nylon rivet 5mm 1 *P100022 or P100049 11, 12, 13, 14, 19, 20, 21, 22, 25, 26, 27(x3), 28(x3),

29(x3), 30(x3), 31, 32, 33, and 34

27 M8 stud 154mm DMC 3 P100022 11, 12, 13, 14, 19, 20, 21, 22, 25, 26, 27(x3), 28(x3),

29(x3), 30(x3), 31, 32, 33, and 34

27 M8 stud 254mm DMC 3 P100049 11, 12, 13, 14, 19, 20, 21, 22, 25, 26, 27(x3), 28(x3),

29(x3), 30(x3), 31, 32, 33, and 34

28 M8 x 32 x 2 flat washer 3 P100083 28, 29, 30, 36 and 37

29 M8 spring washer 3 P100083 28, 29, 30, 36 and 37

30 M8 hex nut 3 P100083 28, 29, 30, 36 and 37

31 Spacer tube 154mm DMC 1 P100022 11, 12, 13, 14, 19, 20, 21, 22, 25, 26, 27(x3), 28(x3),

29(x3), 30(x3), 31, 32, 33, and 34

31 Spacer tube 254mm DMC 1 P100049 11, 12, 13, 14, 19, 20, 21, 22, 25, 26, 27(x3), 28(x3),

29(x3), 30(x3), 31, 32, 33, and 34

32 Locknut 1 P100088 32, 33 and 34

33 O-ring 66 x 2mm 1 P100088 32, 33 and 34

34 Collar 1 P100088 32, 33 and 34

35 Gearbox 44:1 1 P100900 (See page 8 for exploded view)

36 1-4 in key 1 P100083 28, 29, 30, 36 and 37

37 Quick change clip 1 P100083 28, 29, 30, 36 and 37

38 M8 x 25 ss bolt 2 P12487 38(x2), 39(x2), 40(x2) and 41

39 M8 spring washer 2 P12487 38(x2), 39(x2), 40(x2) and 41

40 Ø5-8 x 5-16 washer 2 P12487 38(x2), 39(x2), 40(x2) and 41

41 O-Ring 1 P12487 38(x2), 39(x2), 40(x2) and 41

42 Motor 500 12V 600W 1 P10068 42

42 Motor 500 24V 600W 1 P10069 42

42 Motor 800 12V 1000W 1 P11112 42

42 Motor 800 24V 1000W 1 P11114 42

43 Unipoint 12V and 24V end

cap and brush kit 1 P10066 43

44 Cima 12V brush kit 1 P100807 44

45 Cima 24V brush kit 1 P100808 45

46 Ø5-8" x 1-1/4" washer 1 SP0421 46

47 1-4in key 1 3462 47

48 Capstan 1 4170 48

49 Oil seal 40 x 55 x 8mm 1 P90006 49, 51, 55, 56, 59 and 65

50 Gearbox top 1 P101624 50, 52 and 58(x4)

51 O-ring 90 x 2mm 1 P90006 49, 51, 55, 56, 59 and 65

52 Bush 1 P101624 52

53 Worm wheel 1 3403 53

54 Bush 1 3145 54

*P100022 = 154mm DMC, P100049 = 254mm DMC. See "Figure 6 - Deck clearance variants" on page 6.

(Parts list continued on next page)

Freedom Windlass 11

Parts List (continued)

Item Description Qty Part to order Includes items

55 Sight glass 1 P90006 49, 51, 55, 56, 59 and 65

56 O-ring 20 x 2 mm 1 P90006 49, 51, 55, 56, 59 and 65

57 Worm box 1 3133 57

58 M6 x 40mm capscrew 4 SP0159 58(x4)

59 Oil seal 40 x 55 x 8mm 1 P90006 49, 51, 55, 56, 59 and 65

60 Bearing 12 x 28 x 8mm 1 P90007 60, 62, 63 and 64

61 Worm 1 5950 61

62 Bearing 25 x 47 x 12mm 1 P90007 60, 62, 63 and 64

63 External circlip 1in 1 P90007 60, 62, 63 and 64

64 Internal circlip 47 x 1.85mm 1 P90007 60, 62, 63 and 64

65 Oil seal 25 x 47 x 7mm 1 P90006 49, 51, 55, 56, 59 and 65

66 Capstan Conversion Kit –

154mm DMC 1 P100018 10, 15, 16, 17, 18, 46, 47 and 48

Ordering Spare Parts

When ordering spare parts, please refer to the parts list above and quote the following details.

Freedom Model (marked in chainwheel bi-square, see "Identifying your Windlass" on page 5)

500

500M

800

800M

Serial number (located on gearbox housing)

Power supply

12V

24V

Part details

Part number Description Quantity

12 Freedom Windlass

Rope and Chain Selection Guide

Use the following table to select the correct rope and chain to suit your Freedom windlass.

Rope Type

Chain Type

12mm

3 strand or

8 plait

1/2”

3 strand or

8 plait

14mm

3 strand or

8 plait

9/16”

3 strand 5/8”

3 strand or

8 plait

¼” Acco G40 SL7

7mm DIN 766 - Freedom 500

(P100030) - - -

6mm PWB Grade L

6mm Bradlink SGC

6mm DIN766 Freedom

500M

(P100031)

- - - -

5/16” Acco G40 SL

5/16” Weissenfels - Freedom 800 *

(P100033) - Freedom

800 *

(P100033)

Freedom 800

(P100033)

8mm PWB Grade L

8mm Bradlink

8mm DIN766

8mm Beaver

- Freedom

800M *

(P100034)

Freedom

800M

(P100034)

- -

* Not a recommended Rope/Chain combination

Freedom Windlass 13

Installation

General Requirements

Foredeck layout

• To prevent possible snags, make sure that the area of deck between the windlass and the

bow roller is clear of obstructions.

• The bow roller should have a central groove suitable for the chain size, as shown in

“Figure 13 - Aligning the windlass with the bow roller” on page 15.

• Provide a chain stopper, snubber or cleat to secure the anchor line when under way. Tie the

anchor line to a bollard or cleat when at anchor.

• Use a chain guide if necessary to prevent the chain from running against the deckplate and

potentially causing damage to the windlass.

Chain guide

Deckplate

Figure 9 - Chain guide

Anchor and chain considerations

• When purchasing an anchor, make sure it fits into the bow roller and is self-launching.

• Use a swivel between the anchor and the chain to prevent the line from twisting as the

anchor is raised or lowered.

• To prevent build up of chain on deck causing possible damage, the bow roller must allow the

anchor to free fall immediately when the anchor is deployed.

• Make sure that at least three links of chain are exposed when the anchor is docked

(see “Figure 10 - Clearances in chain locker” on page 14).

14 Freedom Windlass

Required clearances

Position the windlass so that the anchor rope/chain rode falls into the deepest and widest section of

the chain locker and with the clearances shown below.

At least 150 mm (6") clearance under

the motor when all the rope/chain is in

the locker.

At least 150 mm (6") from the centreline

of the windlass to the rear bulkhead of

the chain locker.

Figure 10 - Clearances in chain locker

Position the windlass clear of pulpit, lifelines and bulwark so that there is room to swing the manual

crank handle.

Template

If fitting the windlass to a deck 12 mm (½ ") or LESS in thickness, use the template shown in Figure

11 below. The template is supplied at the back of this manual.

Deck thickness

< 12mm (1/2")

Ø45mm

Figure 11 - Template for decks less than 12 mm (1/2") thick

Freedom Windlass 15

If fitting the windlass to a deck 12 mm (½ ") or MORE in thickness, use the template shown in

Figure 12 in conjunction with the performance plate supplied. The template is supplied at the back

of this manual.

Ø100 mm

Deck thickness

> 12 mm (1/2")

< 65 mm (2 1/4")

Performance

plate

Figure 12 - Template for decks more than 12 mm (½") thick

Aligning the windlass with the bow roller

• The windlass must be positioned to allow the rope/chain rode to have a clear run from the

bow roller to the chainwheel.

• The bow roller should have a vertical groove to suit the profile of the chain. This will align the

chain so that it enters the chainwheel without twisting.

• The windlass should be aligned with the bow roller within the tolerances shown in Figure 13

below.

• The windlass must be installed in accordance with the template supplied.

+/- 5

> 150 mm (6")

Bow Roller

Figure 13 - Aligning the windlass with the bow roller

16 Freedom Windlass

Installation Instructions

Before you start

Before installing the windlass, identify any bulkheads, wiring or piping under the deck. This may

determine where the windlass can be positioned.

Deck thickness

It is imperative that the deck and under-deck pad (not supplied) are of sufficient thickness and

structural strength to support the loads imposed on or by the windlass.

An under-deck pad should spread the load as widely as possible.

Preventing electrolysis

For aluminium boats, it is essential that the deckplate be insulated from the deck with a non-

conductive gasket (not supplied), that the mounting studs pass through insulators (not supplied),

and that the under-deck fastenings are insulated from the deck with fibre washers (not supplied).

It is also important that the anchor and chain are insulated from the hull, including rubber lining the

chain locker and insulating the fixing for the end of the rode to the hull.

Without these precautions, severe electrolysis can occur.

Because the motor is of the isolated earth type, it is not necessary to separately earth the windlass.

Installation procedure

** ATTENTION**

Please note, when installing winch and in particular the chain wheel. The shaft and bronze clutch

cones MUST be coated in Shell Nautilus NLG12 Marine Grease, Castrol Boating Grease, Valvoline

Val Plex EP or equivalent grease. See “Typical Greasing Instructions” on Pg 34.

1. Position the template on the deck using the alignment guidelines on the template.

(See also "Figure 13 - Aligning the windlass with the bow roller" on page 15).

2. Use the template to mark the position of the holes. Drill the holes for the retaining bolts.

Tip: On GRP boats, running the drill in reverse first will reduce chipping of the gel coat.

Using hole saws, cut the holes for the spacer tube and chain pipe.

3. On GRP or wooden decks, seal the edges of the holes with epoxy to avoid ingress of

moisture.

4. For decks thicker than 12 mm (½ ") use the performance plate as shown in Figure 12 on

page 15.

Freedom Windlass 17

5. Use the gasket supplied to seal the windlass to the deck.

For aluminium boats fit a non-conductive gasket to insulate the deckplate from the

deck to prevent electrolysis.

6. Fasten the windlass to the deck using the nuts and washers supplied.

Tighten the nuts progressively and evenly. Do NOT use power tools.

Make sure the installation is firm, but do not over tighten the nuts.

7. Smear a coating of grease on the shaft and fit the gearbox/motor assembly to the

bottom of the spacer tube.

Orientate the motor away from the incoming rope and chain (see "Figure 14"

below) and then hand tighten the plastic locknut.

NOTE: If the unit is going to be mounted in such a way, that it may be tilted, ensure

the drainage slot on the gearbox is at the lowest point to prevent excess water etc.

sitting around the seals.

Drainage Slot

Figure 14 - Motor orientation

18 Freedom Windlass

8. Rotate the shaft by hand (or by using the manual crank handle) to align the keyway

in the shaft with the keyway in the gearbox.

Insert the key into the keyway.

9. Fit the quick-release clip into the groove in the bottom of the shaft to secure the

key.

Make sure the eyelets are facing down and away from the keyway.

10. When tightening the cables to the motor, ensure the lower nut is secure against

turning when tightening the upper nut. This will prevent damage occurring within

the motor.

Upper Nut

Lower Nut

Installing on a sloping or curved deck

Ensure that the windlass has the correct vertical alignment with the bow roller as shown in

"Figure 13 - Aligning the windlass with the bow roller" on page 15.

If necessary, use a mounting pad as shown below.

Figure 15 - Using a mounting pad on a curved deck

Important note to Boat Builders

Experience has shown that on long ocean deliveries as deck cargo, sulphur from the ships exhaust

settles and severely damages the chrome plating and stainless steel of the windlass by breaking

down the protective chrome oxide film.

We suggest that after completing installation you spray the top works of the windlass with CRC

3097 “long life” and wrap the windlass with plastic film and tape.

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Maxwell Freedom 800 Operating instructions

Maxwell Freedom 800 Operating instructions

Maxwell Freedom 800 Operating instructions

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